Laminating Composite Panels - Flakeboard

COMPOSITE PANEL ASSOCIATIONSM 

technical 

BULLETIN 

INTRODUCTION 

Over the past several decades, industrial grade 

particleboard, medium density fiberboard 

(MDF) and hardboard have been recognized 

throughout the wood industry as ideal 

substrates for laminated panel constructions, 

utilizing various types of decorative overlay 

surfacing materials. This publication discusses 

the major types of decorative overlays in detail 

and provides recommendations to the 

laminator on suggested lamination strategies, 

along with technical and performance 

considerations. 

Particleboard has been favored by laminators 

because of its uniform density, thickness 

tolerance and surface smoothness. Other 

board properties such as dimensional stability, 

strength, stiffness, flatness, screw holding 

strength and workability contribute significantly 

to the ease of fabrication and ultimate 

performance of the laminated end product. 

High-pressure laminates, thermally fused 

laminates and resin-saturated decorative 

papers, vinyl films, foils and wood veneers are 

the most common types of overlay materials 

applied to particleboard substrates. 

MDF has become a premier substrate for wood 

veneers, vinyl films, light and intermediate 

Laminating Composite Panels 

basis weight 

decorative papers, 

resin-saturated 

decorative papers 

and foils. Of the 

many properties that 

make MDF desirable 

as a substrate for laminates and overlays, the 

most important are its face and edge qualities. 

As veneers and papers have diminished in 

thickness, substrate quality has become more 

important. MDF's smooth surface, superior 

edge-finishing qualities, dimensional stability, 

flatness, close tolerances, dent-resistance, 

lower glue usage requirements and absence of 

board grain telegraphing have contributed to 

its wide acceptance. Good bond strength, 

screw holding strength and resistance to 

compression and warp also make MDF an ideal 

substrate for lamination with various 

laminating materials. 

The most common lamination processes apply 

overlay material to the substrate by cold or hot 

pressing with either flat (platen) or continuous 

(roll or double belt) laminating presses. 

Because each type of overlay material has 

unique properties and lamination 

requirements, the choice of laminating material 

introduces variables that affect the laminating 

process and influence the performance of the 

finished product. 

1

TABLE OF CONTENTS 

INTRODUCTION ................................................................................................... 1 

DEFINITIONS....................................................................................................... 4 

UNITS OF MEASURE ...................................................................................................4 

OVERLAY MATERIALS ................................................................................................4 

DECORATIVE FOILS........................................................................................................ 4 

HIGH-PRESSURE LAMINATES........................................................................................... 5 

LIGHT BASIS WEIGHT PAPERS......................................................................................... 5 

THERMALLY FUSED PAPERS............................................................................................. 5 

VINYL FILMS.................................................................................................................. 6 

WOOD VENEERS ............................................................................................................ 6 

SUBSTRATES............................................................................................................. 6 

HARDBOARD ................................................................................................................. 6 

MEDIUM DENSITY FIBERBOARD (MDF) ............................................................................. 7 

PARTICLEBOARD............................................................................................................ 7 

REFERENCES ............................................................................................................. 7 

LAMINATING OVERLAYS ...................................................................................... 7 

2 

DECORATIVE FOILS & LIGHT BASIS WEIGHT PAPERS .............................................. 7 

INTRODUCTION ............................................................................................................. 7 

SUBSTRATE REQUIREMENTS ........................................................................................... 7 

PROCESS PARAMETERS .................................................................................................. 8 

ADHESIVES ................................................................................................................... 8 

TROUBLESHOOTING ....................................................................................................... 8 

Telegraphing or Irregular Surface .............................................................................. 8 

Poor Adhesion or Delamination.................................................................................. 8 

HIGH-PRESSURE LAMINATES.................................................................................... 8 

INTRODUCTION ............................................................................................................. 8 

Types of High-Pressure Laminates ............................................................................. 9 

Properties of High-Pressure Laminates ..................................................................... 10 

SUBSTRATE REQUIREMENTS ......................................................................................... 11 

PROCESS PARAMETERS ................................................................................................ 11 

Conditioning Materials ............................................................................................ 11 

Lamination ........................................................................................................... 11 

ADHESIVES ................................................................................................................. 12 

Thermosetting Adhesives........................................................................................ 12 

Thermoplastic Adhesives ........................................................................................ 13 

Contact Adhesives ................................................................................................. 13 

TROUBLESHOOTING ..................................................................................................... 13 

Warp.................................................................................................................... 13 

Delamination ........................................................................................................ 14 

THERMALLY FUSED PAPERS .................................................................................... 15 

INTRODUCTION ........................................................................................................... 15 

Production of the Thermally Fused Decorative Papers................................................. 15 

Laminated Panel.................................................................................................... 16 



Laminating Press ................................................................................................... 16 


Substrate ............................................................................................................. 17 

Pressing Parameters .............................................................................................. 17

ADHESIVES ................................................................................................................. 17 


Warp.................................................................................................................... 18 

Mottling................................................................................................................ 18 

Precure ................................................................................................................ 19 

Starvation ............................................................................................................ 19 

VENEERS ................................................................................................................. 19 

INTRODUCTION ........................................................................................................... 19 




Hot Pressing ......................................................................................................... 20 

Cold Pressing ........................................................................................................ 20 

ADHESIVES ................................................................................................................. 21 


Warp.................................................................................................................... 21 

Delamination ........................................................................................................ 21 

VINYL LAMINATION ................................................................................................ 21 

INTRODUCTION ........................................................................................................... 21 

Cold Laminating System ......................................................................................... 21 

Hot Laminating System .......................................................................................... 22 




Pressing Parameters .............................................................................................. 22 

ADHESIVES ................................................................................................................. 22 

Cold Laminating .................................................................................................... 22 

Hot Laminating...................................................................................................... 22 

VINYL - THERMOFORMING ...................................................................................... 23 

INTRODUCTION ........................................................................................................... 23 

Vacuum Forming ................................................................................................... 23 

Membrane Pressing................................................................................................ 23 





ADHESIVES ................................................................................................................. 24 





APPENDIX I - GLOSSARY OF TERMS ...................................................................25 

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DEFINITIONS 

Units of Measure 

Imperial units of measure have been used 

throughout this document, with the equivalent 

value in metric units of measure given in 

parentheses. One exception is the value for the 

weight per unit area of decorative and other types 

of papers used in the laminating industry, which is 

expressed in metric units of measure. 

The imperial unit used by the decorative paper 

industry in the beginnings of the high-pressure 

industry was BASIS WEIGHT expressed in pounds per 

ream of décor paper, or lbs/3000 square feet. The 

equivalent metric unit is GRAMMAGE, expressed in 

grams per square meter or gsm. Due to 

globalization in the décor and specialty paper 

industry, as well as the spread in the use of metric 

units in North America, the use of the metric unit of 

measure has significantly increased in the 

laminating industry over the last decade or two. 

The metric unit of measure is also easier to 

visualize and was thus chosen as the preferred unit 

to define the weight of décor paper per unit area, 

in this document. 

Conversion of a GRAMMAGE value to a BASIS WEIGHT 

value can be accomplished by multiplying the 

GRAMMAGE value by 0.6154. Conversely, a 

GRAMMAGE value can be obtained by multiplying a 

BASIS WEIGHT value by 1.6248. 

Overlay Materials 

Decorative Foils 

Decorative foils are alpha-cellulose papers with 

grammages ranging between 40 and 200 grams/ 

m 2 . These overlays are also referred to as 

impregnated papers. Because of substrate surface 

advancements, the use and performance of 

decorative foils has increased. Common 

applications of decorative foils include cabinets, 

store fixtures, closet systems, ready-to-assemble 

(RTA) and home office furniture, profile wrappings 

and point-of-purchase (POP) displays. 

Decorative foils are impregnated with a blend of 

resins; the type of resin used is dependent on the 

final application of the laminated panels. The 

impregnation will add between 20% and 50% to 

the weight of the decorative paper, depending on 

the type and process of impregnation. Foils are 

classified as unimpregnated, pre-impregnated or 

post-impregnated: 

UNIMPREGNATED FOILS – no resin is added during 

paper manufacturing. 

PRE-IMPREGNATED FOILS – these papers are 

impregnated during the paper-making process with 

a resin system such as melamine and/or acrylic. 

This impregnation normally takes place on the 

paper machine; however, some or all of the resins 

can be added to the cellulose before calendering. 

POST-IMPREGNATED FOILS – are impregnated with 

resin after the paper-making process is completed. 

The impregnation is accomplished with a blend of 

melamine and acrylic resins. Due to the high 

percentage of resins in the paper, acrylic is 

normally necessary to retain flexibility after curing. 

Quantity, method and type of impregnation, along 

with the type of adhesive system and substrate 

used, will have a direct effect on the internal bond 

strength and surface porosity of the finished 

product. These qualities will be demonstrated in 

cutting and machining performance. Laminated 

foils have good fidelity of print or solid color, and 

provide a finished panel with good resistance to 

stain, chemicals, abrasion, and impact. In most 

cases, foils can be used for single-side laminated 

panels to provide a more cost-effective 

construction. 

The resins in pre-impregnated and postimpregnated 

decorative foils are fully cured in the 

foil manufacturing process and do not have residual 

bonding properties. Therefore, impregnated as 

well as unimpregnated decorative foils require an 

adhesive system for bonding to the substrate. 

Depending on the laminating equipment to be 

used, foils may be supplied by the overlay 

manufacturer with a pre-applied hot melt adhesive. 

Additionally, a variety of in-line laminating 

adhesives may be used. The most common of 

these adhesives is polyvinyl acetate (PVA). Other 

systems such as urea formaldehyde, acrylic basedor 

hot melt adhesives can be applied in-line. The 

type of adhesive system used and its method of 

application can affect the performance of the 

finished panel. 

Impregnated papers do not require a topcoat to be 

considered a foil, however, depending on the 

application, a finished topcoat will normally be 

added. The finish is the reason the product is 

referred to as a “Finished Foil” in Europe. This 

nomenclature is rarely used in North America. 

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High-Pressure Laminates 

High-pressure laminates (HPL) are also known as 

plastic laminates. In its LD 3-2005 standard 

publication, entitled "High-Pressure Decorative 

Laminates" the National Electrical Manufacturers 

Association (NEMA) defines a high-pressure 

laminate as a sheet "which consists of papers, 

fabrics, or other core materials that have been 

laminated at pressures of more than 5.0 MPa 1 

using thermosetting condensation resins as 

binders." The most common resins used are 

phenol-formaldehyde and melamine-formaldehyde 

thermoset resins. 

The great majority of high-pressure laminates used 

as overlays on wood substrates are produced by 

stacking an optional alpha-cellulose sheet and a 

decorative paper sheet, both impregnated with 

melamine resin, over multiple Kraft paper sheets 

impregnated with phenolic resin, and fusing the 

sheets together in a press, at temperatures 

exceeding 265°F (130°C) and pressures as high as 

1,200 psi (8274 MPa). The optional alpha-cellulose 

sheet, popular in laminate flooring products, 

becomes transparent during the pressing process; 

it is used mainly with print patterns to add 

additional wear resistance to the surface. The final 

thickness of the laminate is determined by the 

number of layers of Kraft paper, the amount of 

resin absorbed by the paper and the pressure used 

in the press. The surface finish (i.e., texture and 

gloss level) is imparted to the surface of the 

laminate while the laminate is being pressed, by a 

textured steel caul plate or an embossed release 

paper sheet. HP laminates are available in a 

multitude of solid colors, printed patterns and 

textures, in sheets of different dimensions. HP 

laminate is a thin, stiff, strong, hard and abrasionresistant 

material that has excellent aesthetic 

appeal and durability. It is overlaid on 

particleboard or MDF substrates for both vertical 

and horizontal end use applications, such as 

tabletops, countertops, sink tops, furniture, 

cabinetry and case goods. 

Light Basis Weight Papers 

Light basis weight papers range in grammage from 

23 to 50 grams/m 2 . Resin may be added during 

the paper making process to improve the internal 

bond strength of the paper. Acrylic, polyester and 

other resins are most commonly used. The paper 

is then printed and generally coated with a 

polyurethane, urea, polyester, acrylic or melamine 

resin, or a combination thereof, for increased 

durability and performance. These very thin 

papers can be printed with excellent quality, high 

fidelity wood grain patterns. Light basis weight 

papers have long been popular with higher levels 

of value engineering and are widely used in 

cabinets, store fixtures, shelving, closet systems, 

ready-to-assemble (RTA) and home furniture. 

Light basis weight papers are usually divided into 

two categories, depending on the amount of resin 

present in the base paper. Light basis weight 

papers containing a lower amount of resin offer an 

economical laminate for use on low wear surfaces, 

such as wall paneling. Papers having a higher 

resin content are characterized by a greater 

internal bond strength. 

Light basis weight papers may be supplied precoated 

with hot melt adhesive ready for hot roll 

laminating, or uncoated, requiring application of an 

adhesive during lamination to the board substrate. 

Light basis weight papers are normally supplied 

with a topcoat to provide surface durability; 

however, they may also be supplied without this 

topcoat and “finished” after lamination. 

Thermally Fused Papers 

The papers in this overlay category are referred to 

by many names, including saturated papers, low 

pressure papers, direct pressure or simply 

melamine overlays, and are used in low-pressure/ 

thermofusing lamination. Sub-categories include 

polyesters and decorative phenolics. These 

decorative papers generally have grammages 

between 60 and 130 grams/m 2 , and their paper 

formation is similar to the formation of the 

decorative sheets used for HPL. They are 

saturated with reactive resins, which are then 

partially cured by the manufacturer, to aid in 

storage and handling of the paper. Full curing is 

achieved in the laminating hot press, when the 

resins form hard, permanent, thermoset bonds 

between the paper and the substrate. 

Thermally fused papers are self-bonding, i.e., the 

resin in the paper flows into the board during 

lamination to create a permanent bond between 

the decorative surface and the board substrate. 

Thus, no additional adhesive system is necessary. 

The three most common thermoset resin systems 

used in the production of saturated papers for lowpressure/thermofusing 

lamination are melamineformaldehyde, 

polyester and decorative phenolic 

resins. When double-stage impregnation 

equipment is available, saturating ureaformaldehyde 

resin may be used to extend the 

melamine resin in the core of the saturated sheet. 

Common end-use applications of thermally fused 

papers include laminate flooring, kitchen cabinets 

and countertops, shelving, store fixtures and home 

office furniture. 

1 725 lb/in 2 5

6 

Vinyl Films 

Vinyl films are made from polyvinyl chloride and 

can be used in a multitude of applications. They 

come in a variety of thicknesses, from 0.002 to 

0.045 inches (0.051 to 0.11 mm), and different 

grades of flexibility. These types of overlays are 

typically extruded or calendered and are divided 

into six categories: 

2 MIL (0.051MM) REVERSE-PRINTED RIGID FILM – 

The print design and base coat are printed on the 

back of a transparent film, in reverse order (i.e. the 

print is applied first followed by the base coat). 

These films are used for wall paneling (mostly in 

recreational vehicles), kitchen cabinets, furniture 

and manufactured housing. 

SEMI-RIGID CLEAR FILM – These films are reverseprinted. 

They are frequently embossed and can be 

coated with scuff resistant coatings. They range 

from 4 to 8 mils (0.10 to 0.20 mm) in thickness. 

Some can be miter-folded. 

SANDWICH FILM – These are semi-rigid, two-ply 

overlays. The opaque base film is top-printed and 

a clear overlay is laminated on top of the printed 

film. These films are designed for miter-folding 

and flat sheet lamination, and range from 5.5 to 8 

mils (0.14 to 0.20 mm) in thickness. Some are 

available with scuff-resistant top coating. 

SOLID COLOR FILM – These are semi-rigid films. 

The film is integrally colored and can be top-printed 

and/or embossed. Top-printed films are used 

extensively in manufactured housing, recreational 

vehicles, commercial paneling and movable walls. 

Plain solids are used in furniture, kitchen cabinets, 

fixtures and displays, and in office furniture 

applications. They range in thickness from 3.5 to 

8.0 mils (0.089 to 0.20 mm). Some films are 

available with scuff-resistant top coatings. 

THERMOFORMED OVERLAY FILM – These films have 

a single-ply or two-ply construction. Gauges range 

from 0.010 to 0.030 inches (0.25 to 0.76 mm), and 

the films may be printed with a wood grain or 

decorative pattern. They may also be embossed 

and/or coated with scuff and stain-resistant 

coatings. Primers to promote adhesion are 

available. These films are designed for 

thermoforming with heat and pressure in a 

membrane press or vacuum forming process. 

Decorative effects can be achieved with two-ply 

films when a router is used to expose a different 

color in the bottom ply of the film. The films may 

also be flat laminated or miter-folded. Raised 

panel cabinet doors and free-formed furniture 

components are the most popular applications for 

this type of film. 

WRAPPING FILMS – These are rigid vinyl films in 

gauges ranging from 0.005 to 0.010 inches (0.13 

to 0.25 mm). The films may be printed with a 

wood grain or decorative pattern, may be 

embossed and/or may be coated with scratch- and 

stain-resistant coatings. These films are designed 

for wrapping profiles, like picture frames and 

furniture molding, and also can be flat laminated 

and miter-folded. 

Wood Veneers 

The veneers used in the lamination industry include 

real wood veneers that are rotary cut, flat cut, rift 

cut or quarter cut from a variety of wood species, 

both domestic and imported. The veneers are 

sliced or peeled to a thickness between 1/25 to 

1/50 inch (1.0 to 0.50 mm) and are available with 

a paper or fleece backing, providing varying 

degrees of flexibility. The backers also provide 

stability and strength to the veneer and minimize 

splintering, cracking and checking. 

Veneers can be overlaid either with heat-activated 

resins or by cold pressing. The main resin used in 

hot-pressing systems is a urea-based adhesive, 

due to its ability to make the panel more rigid, its 

faster processing parameters and lower cost base. 

Cold press systems typically use polyvinyl acetate, 

casein and contact adhesives. These systems are 

used for smaller production quantities and may be 

less rigid than heat-activated adhesive systems. 

Veneered composite panel constructions are used 

in many applications, including high quality 

furniture, case goods, store fixtures and cabinetry. 

Some veneers are used for profile wrapping, 

typically over MDF, for high-end millwork 

applications. 

Substrates 

Hardboard 

Hardboard is a composite panel manufactured 

primarily from inter-felted ligno-cellulosic fibers 

consolidated under heat and pressure. Other 

materials may be added during the manufacturing 

process to improve certain properties, such as 

resistance to abrasion and moisture, and increased 

strength and durability. Hardboard has a uniform 

thickness, density and appearance, and has no 

grain. It resists marring, scuffing and abrasion. It 

can be laminated with paper overlays, plastic 

laminates and veneers.

Medium Density Fiberboard (MDF) 

MDF is a composite panel product typically 

consisting of cellulosic fibers combined with a 

synthetic resin or other suitable bonding system 

and joined together under heat and pressure. 

Additives may be introduced during manufacturing 

to impart additional characteristics. The surface of 

MDF is flat, smooth, uniform, and dense, and has a 

homogeneous edge profile, free of knots and grain 

patterns. 

Particleboard 

Particleboard is a composite panel product 

consisting of cellulosic particles of various sizes 

that are bonded together with a synthetic resin or 

binder, under heat and pressure. Particle 

geometry, resin levels, board density and 

manufacturing processes may be modified to 

produce products suitable for specific end uses. At 

the time of manufacture, additives can be 

incorporated to provide greater dimensional 

stability, better fire and moisture resistance or to 

impart additional characteristics. 

References 

NEMA LD 3-2005, "High-Pressure Decorative 

Laminates", NEMA Standard Publication, 

National Electrical Manufacturers Association, 

Copyright 2005. 

“Particleboard from Start to Finish”, Composite 

Panel Association, Copyright 1996. 

“Glossary of Terms”, Laminating Materials 

Association, Copyright 1991. 

“2005 Buyers & Specifiers Guide to 

Particleboard and MDF”, Composite Panel 

Association, Copyright 2005. 

LAMINATING OVERLAYS 

Decorative Foils & Light Basis Weight 

Papers 

Introduction 

Decorative foils and light 

basis weight papers are 

decorative overlays that are 

either roll laminated or 

pressed in “quick stamping” 

platen presses. Foils are 

thicker and have a higher 

basis weight than light basis 

weight papers. Decorative 

foils are available in printed 

patterns or in solid colors. Foils are classified as 

unimpregnated, pre-impregnated or postimpregnated: 

 

 

 

Unimpregnated foils do not contain resin, i.e., 

no resin is added during the paper 

manufacturing process. 

Pre-impregnated foils are impregnated during 

the paper-making process with a resin system 

such as melamine and/or acrylic. This 

impregnation normally takes place on the 

paper machine; however, some or all of the 

resins can be added to the cellulose before 

calendering. The calendering process provides 

a good printable surface that takes topcoating 

easily. The product can be embossed either 

chemically or mechanically. The foil will remain 

flexible, even after the resins are fully cured. 

Post-impregnated foils are impregnated with 

resin after the paper-making process is 

completed. The impregnation is accomplished 

with a blend of melamine and acrylic resins. 

Due to the high percentage of resins added, 

acrylic is normally added to retain the flexibility 

of the foil after the resins are cured. The resin 

mixture encapsulates the paper fibers and fills 

voids in the base paper. The papers may be 

printed and topcoated. Chemical and 

mechanical embossing is also possible. 

The resins in pre-impregnated and postimpregnated 

decorative foils are fully cured in the 

foil manufacturing process and do not have 

residual bonding properties. Therefore, these foils 

require an adhesive system for bonding to the 

substrate. The adhesive can be pre-applied to the 

foil as hot melt or a wet application can be 

performed in-line, when laminating the foil to the 

substrate. A number of vendors supply press 

equipment and there are several methods of 

bonding the foil to the substrate, either in a oneside 

or a two-side application. 

Substrate Requirements 

Industrial grade MDF and particleboard are good 

substrates for decorative foils and light basis 

weight papers because they have uniform and 

smooth sanded surfaces. As the basis weight of 

the paper is diminished, the quality of the 

substrate surface becomes more important. The 

best substrate surfaces are achieved through the 

use of finer grit belts and cross belt sanders. 

Substrate surfaces need to be clean and the boards 

need to be flat. Thickness control is critical within 

the board and between boards, especially on roll 

laminating lines. Both MDF and particleboard have 

shown that they process very well, due to precise 

thickness control. Surface strength, surface 

porosity, and surface wettability are also important 

7

8 

factors in running the lines smoothly, achieving 

excellent paper adhesion and displaying superior 

aesthetics. 

Process Parameters 

Since so many different approaches are used, it is 

hard to give specific parameter recommendations. 

Uniform application of adhesives and catalysts, if 

used, are critical. These materials may be applied 

to the panel, to the paper, or both, depending on 

the equipment. Successful lamination also is 

dependent on the paper uniformity and its bonding 

properties. 

The surface temperature of the materials 

(substrate, adhesive, catalyst and paper) can affect 

the cure speed and the penetration of the bonding 

ingredients. Control of the substrate temperature 

lies with the laminator, through the use of 

warehouse HVAC systems or processing line 

configuration. Time between glue application or 

activation and application of pressure for 

lamination, as well as adhesive application rates, 

must be carefully controlled. Adequate and 

uniform press or nip pressure is essential for good 

lamination. 

Adhesives 

Various adhesive systems are used with decorative 

foils and light basis weight papers. The most 

common are polyvinyl acetate (PVA), urea 

formaldehyde and acrylic-based systems. Hot melt 

adhesives are used also, either pre-applied or 

applied in-line. The choice of adhesive system can 

affect the performance of the finished panel. 

When applying waterborne adhesives such as PVAs, 

EVAs (ethylene/vinyl acetate) and ureaformaldehydes 

to the substrate surface, rapid 

flashing-off of the water is essential to prevent 

fiber swell. The adhesive supplier’s 

recommendations should be closely followed to 

achieve adequate curing of the adhesive and obtain 

good paper adhesion. The type of adhesive 

selected is dependent upon factors such as the 

type of overlay, the substrate and the laminating 

equipment used. The equipment manufacturer or 

adhesive manufacturer should be contacted in 

selecting the correct adhesive for a particular 

application. The above comments also apply to 

catalysts. 

Troubleshooting 

Telegraphing or Irregular Surface 

Telegraphing and/or irregular surface on the 

laminated panel surface may be due to: 

Improper functioning of the substrate 

cleaning equipment, i.e., cleaning brushes 

at the feed end of the line. 

Contamination in the adhesive or catalyst 

systems. 

Improper substrate storing conditions. 

Extended or improper storage of the 

substrate can lead to fiber pop or grain 

raise, especially on the top and bottom 

boards in a unit; controlling the inventory 

cycle is important. 

Surface defects present on the substrate 

prior to lamination. This can be determined 

by applying crayon to the surface of a board 

sample from the same unit as the defective 

panel or by using a flashlight to view its 

surface at a low angle. 

Prolonged time between glue application, 

and application of the laminating roll or 

plate. This may cause fiber pop on the line, 

due to extended contact between the 

catalyst and/or adhesive and the substrate 

surface, prior to lamination. 

Poor Adhesion or Delamination 

Adhesion problems may be due to: 

Application of incorrect levels of catalyst 

and/or adhesive. 

Insufficient wetting of the substrate and/or 

paper surfaces by the catalyst and/or 

adhesive. 

Incorrect equipment settings such as 

temperature, pressure, or press roll or line 

speeds. 

Improper curing of the adhesive system. 

Incorrect substrate target thickness or 

inadequate thickness tolerance. 

Incorrect surface temperatures of the 

mating materials (substrate, resin, paper, 

catalyst). 

High-Pressure Laminates 

Introduction 

High-pressure laminates (HPL) are 

produced by fusing together under 

heat and pressure, multiple layers 

of Kraft paper saturated with 

phenolic resin, a layer of 

decorative paper saturated with 

melamine resin and, optionally, a 

very thin top sheet of alphacellulose 

paper heavily saturated 

with melamine resin. The 

resulting laminate is a thin, stiff, strong, hard and 

abrasion-resistant sheet with excellent aesthetic

appeal and durability. High-pressure laminates are 

most often manufactured using a multi-opening 

press, with several laminates being pressed 

simultaneously in each press opening. A relatively 

new development in HPL technology is the 

continuous press, which uses rolls of resinsaturated 

papers instead of sheets, to produce 

laminates in a continuous fashion; only thin 

laminates can be produced with this process. The 

laminates are rolled or cut to the desired length as 

they exit the continuous press. The thinner 

continuous HP laminates can be applied to the 

substrate using a roll press. 

High-pressure laminates are available in a wide 

range of solid colors, wood grain prints, patterns, 

textures and finishes. They are overlaid on 

particleboard or MDF substrates for both vertical 

and horizontal end use applications such as 

tabletops, countertops, sink tops, furniture, 

cabinetry, and case goods. The type and 

properties of the high-pressure laminate selected 

will depend on the desired performance of the end 

product. 

In addition to the aesthetic attributes, the 

lamination of particleboard or MDF with HP 

laminates can improve the physical performance of 

the substrate. The bending strength and stiffness 

of particleboard or MDF can increase significantly 

with the addition of HP overlays on each side. For 

example, standard ¾-inch industrial grade 

particleboard (ANSI A208.1, M-2) has a Modulus of 

Elasticity (MOE, bending stiffness) of about 

326,300 psi and a Modulus of Rupture (MOR, 

breaking strength) of about 2,100 psi. After 

laminating with a 0.062–inch HPL face and a 

0.030–inch backer, strength in the forming 

direction increases as reflected by an MOE of 

850,000 psi and an MOR of 6,500 psi for the 

laminated panel. In an application-oriented 

example, a shelf of ¾–inch industrial (M-2) 

particleboard that is 24 inches long will carry 45 

lbs per square foot of uniform loading with a 

0.133–inch deflection. If laminated as described in 

the preceding example, it can carry 85 lbs per 

square foot before reaching the same deflection. 

Types of High-Pressure Laminates 

Different types of high-pressure laminate materials 

designed to meet specific requirements are 

available from suppliers, in various sheet sizes and 

thicknesses. Based on their use, they are broadly 

identified as general purpose, postforming and 

backer laminates. Special purpose laminates are 

also produced that possess very specific properties 

for particular applications. 

GENERAL PURPOSE - General Purpose laminates are 

the most widely used, because they are suitable 

for almost any horizontal or vertical surface 

applications. Typical thickness ranges from 0.028 

to 0.048 inch (0.71 to 1.22 mm). 

POSTFORMING - Postforming laminates are 

laminates that can be formed around curved edges 

by application of heat and restraint, followed by 

cooling. Their maximum thickness is about 0.038 

inch (0.97 mm); these laminates can normally be 

formed or soft roll-formed to radii as small as 3/8 

inch (9.5 mm) or less. Typical uses are cupboard 

door edges and counter bullnoses and cove bends. 

BACKER - Backer laminates are laminates produced 

without a decorative face that are used on the 

back of panel assemblies to protect the substrate 

from changes in humidity and to balance the panel 

construction. There are two major types of HP 

backers: standard and regrinds. Non-HP backers 

are also being produced by several manufacturers. 

Standard Phenolic Backers 

These are the most common type of backers used 

and they are manufactured specifically for this 

purpose. They are usually slightly thinner than 

decorative HPL sheets and do not have a melamine 

top sheet, so their physical properties are slightly 

different than those of decorative HP laminates. 

Regrinds 

These are produced from decorative HP laminates 

that have been rejected due to some surface flaw 

or defect. The rejected decorative laminates are 

made into backers by sanding off their decorative 

face. This is the best type of backer for HP 

laminates, because it has essentially the same 

thickness and properties as the decorative 

laminate. It therefore provides the best balanced 

panel construction. 

Non-HP Backers 

These backers are paper products manufactured 

through a process other than high-pressure 

lamination. They are used as substitutes for 

standard HP backers, in an effort to reduce 

laminated panel production costs. As a group, 

they have different properties than HP laminates 

and may not provide balanced panel construction. 

OTHER TYPES OF HIGH-PRESSURE LAMINATES - 

Special purpose high-pressure laminates include 

cabinet liners, high-wear, fire-rated, electrostatic 

dissipative and chemical resistant laminates; they 

are purchased by fabricators to meet specific end 

product requirements. 

9

10 

Properties of High-Pressure Laminates 

Physical Properties 

In addition to aesthetic attributes, the lamination of 

particleboard or MDF with HPL can improve the 

physical performance of the substrate. Highpressure 

laminates are considerably stronger and 

stiffer per unit thickness than particleboard or MDF. 

For example, the tensile strength of HPL is 

anywhere from 10 to 35 times greater than that of 

particleboard. This means that HP laminates have 

enough strength to affect the particleboard or MDF 

substrate when they expand and contract in 

response to changes in ambient humidity 

conditions. 

Particleboard and MDF panels are isotropic 

materials. Their physical properties are 

independent of direction, as shown by the fact that, 

for example, the modulus of rupture will be the 

same, whether the sample used in the 

measurement was cut parallel to the width of the 

board or parallel to its length. On the other hand, 

HP laminates are anisotropic or unidirectional 

materials, i.e., they have different characteristics in 

different directions. This is due the fact that the 

anisotropic properties of the paper sheets used in 

the manufacturing of HP laminates are retained in 

the laminate. Anisotropic properties are typical of 

paper products. They are usually much stiffer, 

stronger, and more dimensionally stable in the 

machine direction (parallel to the paper-forming 

direction). This carries over to the physical 

properties of HP laminates. HPL machine direction 

is generally parallel to the sander markings on the 

back of the sheet, although there are exceptions. 

The best way to determine machine direction is to 

flex the laminate: the direction parallel to the 

machine direction is always stiffer. Identification of 

the machine direction of the laminate is important 

for the production of laminated panel constructions 

with optimal performance. 

Dimensional Stability 

High-pressure laminates do not respond to changes 

in moisture content in the same manner as 

particleboard and MDF. Linear expansion and 

contraction in the machine direction is less than 

particleboard or MDF and approximately twice as 

much as particleboard in the cross-machine 

direction (perpendicular to the machine direction). 

Standard HPL backer sheets often show even 

greater differences in dimensional stability than 

decorative HPL sheets, with movement in the 

cross-machine direction up to four or five times as 

much as in the machine direction. Standard backer 

sheets also may pick up and lose moisture more 

rapidly than the thicker decorative HPL sheets. 

The properties of HPL will vary from one 

manufacturer to another. Thus, laminates from 

different manufacturers should not be mixed on the 

same panel construction, unless they are known to 

have the same behavior pattern. 

Performance Standards 

The U.S. performance standard for HPL decorative 

laminates is identified as ANSI/NEMA LD 3-2005, 

"High-Pressure Decorative Laminates." This 

standard is written by the National Electrical 

Manufacturers Association (NEMA). A copy can be 

downloaded free of charge by visiting the NEMA 

website at www.nema.org. A hard copy can also 

be ordered on the same web site or by telephone 

at 1-800-854-7179. 

The Canadian performance standard, CAN3-A172- 

79M, "High-Pressure Paper Base Decorative 

Laminates" has been withdrawn. 

The European performance standard EN 438, 

"High-Pressure Decorative Laminates (HPL) – 

Sheets Based on Thermosetting Resins (usually 

called laminates)" was revised in July 2005. 

The ISO performance standard, ISO 4586, "High- 

Pressure Decorative Laminates (HPL) – Sheets 

Based on Thermosetting Resins" was revised in 

October 2004.


As indicated previously, particleboard and MDF 

have many desirable properties that make them an 

ideal substrate for panel constructions overlaid 

with decorative HPL faces. Because board 

properties and sanding quality can vary from one 

manufacturer to another, the fabricator should 

thoroughly test and evaluate candidates until 

satisfied they meet all requirements for the 

finished product. It is also a good practice to 

establish written specifications with board suppliers 

to cover specific needs. Because HPL is generally 

quite thick and rigid, extremely fine-sanded 

surfaces, especially with MDF, are not normally 

considered important properties by HPL laminators. 


An important requirement for tabletops, 

countertops, sink tops and other laminated panels 

is their ability to stay flat under normal service 

conditions. If proper laminating methods are not 

observed, warped constructions will result. The 

causes for warped panel constructions need to be 

recognized and understood to minimize their 

potential for occurring during and after fabrication. 

These are described in detail in the 

Troubleshooting section. 

Conditioning Materials 

areas of concern for producing quality HP 

laminated panel constructions are: 

Substrate 

Substrate surfaces should be clean and free of any 

loose particles or contaminants that could interfere 

with adhesive application or affect appearance of 

the finished laminate by telegraphing. 

Glue Spread 

Adhesive should be spread to a uniform thickness 

over the entire substrate surface. Globs, ridges, 

lines, and starved areas that could telegraph 

through the HPL face or cause poor or spotty 

bonds should be avoided. 

Care should be taken not to use any more 

adhesive than required to achieve good transfer 

between mating materials. Excessive glue usage 

adds more moisture to the board surface that 

could promote surface roughening and affect the 

appearance of the finished laminates. Costs are 

also increased. Glue spreads should be verified 

often with a film thickness gauge or in accordance 

with the formulas given below, to ensure adequate 

glue spread. 

Formulas for Determining Glue Spread or Glue 

Requirement (Single Glue-Line) 

It is essential to bring the HP laminate sheets (face 

and backer sheets) and the intended substrate 

(particleboard or MDF panels) to equilibrium at the 

same relative humidity and temperature before 

lamination. A conditioning period of at least one 

week, but preferably two weeks, between 35% and 

45% relative humidity and at a temperature 

around 70F (21C) is recommended. The longer 

period is preferred because both the substrate and 

the HP laminate require at least seven days to 

reach equilibrium. 

If laminated panels are fabricated from component 

materials conditioned at radically different 

temperatures or humidity levels, warp will surely 

occur when all of the materials come to equilibrium 

with the surrounding atmosphere. 

Additional information about conditioning is 

available in CPA’s technical bulletin 2 , “Storage and 

Handling of Particleboard and MDF.” 

Lamination 

Regardless of the laminating process employed, 

the adhesive manufacturer’s recommendations for 

storage, method of application, and use of the 

adhesive should be closely followed. The main 

The following formulas may be used to determine 

glue spread, G, in pounds of glue per 1000 

square feet of laminating surface area, for a 

single glue line. 

When weighing in grams: 

Glue Spread = (W g – W s ) x 1000 sq. ft. 

453.6 g/lb 

where: 

W s is the weight of 1 square foot of substrate, in 

grams; 

W g is the weight of 1 square foot of substrate with 

glue applied, in grams. 

When weighing in ounces: 

2 “Storage and handling of Particleboard and MDF”, Composite Panel Association, Copyright 2000. 

Glue Spread = (W g - W s ) x 1000 sq. ft. 

16 oz/lb 

where: 

W s is the weight of 1 square foot of substrate, in 

ounces; 

W g is the weight of 1 square foot of substrate with 

glue applied, in ounces. 

11

The following formulas may be used to determine 

the weight of glue required per square foot of 

laminating surface area to obtain a desired glue 

spread. 

Grams of glue required/sq. ft. = G x 453.6g/lb 

1000 sq. ft. 

where: 

G is the glue spread in pounds per 1000 square 

feet. 

Ounces of glue required/sq. ft. = G x 16oz/lb 

1000 sq. ft. 

where: 

G is the glue spread in pounds per 1000 square 

feet. 

Contamination 

Possible sources of contamination of the adhesive 

and surfaces to be glued should be eliminated. 

Basic housecleaning practices can practically 

eliminate the possibility of foreign matter being 

trapped in the laminate layup. Adhesive coating 

equipment, caul plates and press or nip rolls should 

be kept clean. 

Pressure 

Adequate pressure is mandatory to ensure good 

transfer of adhesive to uncoated surfaces and to 

hold components in close contact while the 

adhesive sets. Most adhesives contract as they set 

and have limited ability to bridge voids or gaps, so 

mating surfaces must be forced together tightly to 

obtain uniform bonds. 

Liquid adhesives should be pressed between 20 

and 50 psi (138 and 345 kPa) or until a small bead 

of adhesive has squeezed out around the panel 

edges. With contact adhesives, nip roll pressures 

of 50 to 75 psi (345 to 517 kPa) for steel or 50 to 

80 durometer rubber rolls are recommended. 

Laminating pressure can be calculated using the 

formula shown below. 

Formula for Calculating Laminating Pressure 

P is the gauge pressure, in psi; 

A is the total panel area, in square inches. 

Temperature and Moisture Content 

When cold gluing, the temperature of the materials 

should be maintained at 70°F (21°C), until the 

adhesive is set. Moisture content will not be a 

factor if the materials have been conditioned before 

laminating, as recommended. 

Layup 

When stack gluing, panels should be laid up faceto-face 

and back-to-back, for smoother finished 

surfaces. 

Adhesives 

A variety of adhesives has been found satisfactory 

for bonding HPL to particleboard and MDF 

substrates. The type of adhesive selected will 

depend upon the desired end product and the 

fabricator’s capabilities. The most commonly used 

adhesive categories are thermosetting, 

thermoplastic and contact adhesives. Their 

properties are described below. 

Thermosetting Adhesives 

These adhesives cure at room temperature or in a 

hot press by chemical reaction, to form a network 

of rigid bonds (crosslinks) that are not re-softened 

by subsequent exposure to heat. The most 

commonly used are: 

Urea-Formaldehyde Adhesives: these are 

good for most applications and provide a 

poor to fair resistance to moisture. 

Resorcinol and Phenol-Resorcinol Adhesives: 

these are used where waterproof bonds and 

good heat resistance are required. 

Casein Adhesives: these are used in 

applications where moisture resistance is not 

critical. 

Epoxy Adhesives: these are good for bonding 

to impervious substrates such as metal, but 

also perform well on almost all substrates. 

Epoxies have good gap-filling properties. 

where: 

SP = R x N x P 

A 

12 

SP is the panel surface pressure, in psi; 

R is the ram area cross section, in square 

inches; R = 0.785xD² where D = diameter 

of the ram in inches; 

N is the number of rams;

Thermoplastic Adhesives 

These adhesives harden at room temperature 

through loss of water or solvent and re-soften 

upon subsequent exposure to heat. The most 

commonly used are: 

 

 

Polyvinyl Acetate Adhesives (White Glue): 

these are good for bonding HPL to wood 

substrates, but have poor moisture and 

heat resistance; they are not 

recommended for sink tops. 

Catalyzed Polyvinyl Acetate Adhesives: 

these are good for most applications; 

they yield moisture-resistant or 

waterproof bonds, depending upon the 

formulation used. 

Contact Adhesives 

Contact adhesives can be water- or solvent-based 

and are suitable for bonding HPL to most 

substrates. They must be applied to both mating 

surfaces and dried before bonding. Laminating can 

be accomplished at room temperature. Highstrength, 

water-resistant bonds are developed 

almost immediately upon contact between both 

coated surfaces. The glue line remains flexible, 

allowing the HP laminate to expand and contract 

independently of the substrate, which minimizes 

the tendency of the finished panel to warp 

(particularly for one-sided constructions). 


Warp 

The causes for warped panel constructions need to 

be recognized and understood to minimize their 

potential for occurring during and after fabrication. 

These are described in detail below. 

Unbalanced Two-Sided Construction 

The basic cause of warp is an unbalanced panel 

construction, i.e. the individual components of a 

laminated panel do not respond equally to changes 

in moisture content. When one considers that 

decorative HPL faces, substrates and backer sheets 

typically expand and contract differently in 

response to changes in relative humidity, it is easy 

to understand why a laminated panel can become 

distorted. Bonding these dissimilar materials 

rigidly together causes internal stresses each time 

the components attempt to change dimensions 

with changes in ambient humidity. Warp results 

when these stresses are not counterbalanced 

within the laminated panel construction. 

Unbalanced constructions may arise from: 

Different Expansion Properties - Warp will 

occur when the HPL face and backer sheet 

do not expand and contract equally with 

changes in moisture content. As thin as 

they are, these materials are strong 

enough and different enough in response to 

ambient humidity changes to profoundly 

affect flatness of the laminated panel. 

Cross Orientation of HPL Sheets - The HPL 

face and backer sheets must be laid up 

with their machine direction parallel to each 

other. If machine directions are crossed, 

“saddle-shape” warp will occur, due to the 

anisotropic characteristics of the HP 

laminates. 

Improper Conditioning - Improper 

conditioning of the component materials is 

a major cause for warp in HPL panel 

constructions. Warp can occur when the 

different materials are not conditioned at 

the same relative humidity before they are 

bonded together. As a result, the 

components expand and contract unequally 

in response to changes in ambient 

humidity, causing warp. It is unlikely that 

panels warped from improper conditioning 

will regain their flatness. If it is not 

practical to condition the components 

because of time restrictions, it is probably 

best to have the decorative HPL face drier 

than the backer sheet at the time of layup. 

If warp does occur, it will be convex toward 

the face and may be less objectionable 

than a concave warp. 

Thin Backer Sheet - Insufficient 

conditioning can aggravate warp when thin 

backer sheets are used. Thin backers 

condition more rapidly than decorative 

faces and can cause warp if they are laid up 

with partially conditioned HPL faces. 

In summary, a balanced panel construction is one 

that will not warp when subjected to forces 

induced by uniformly distributed moisture changes. 

The key factors for obtaining a balanced panel 

construction are: 

Proper conditioning of the component 

materials before lamination. 

Selection of HPL faces and backers with 

similar linear expansion properties. 

Laying up of the HPL faces and backers 

with their machine direction parallel to each 

other. 

Always using an HPL backer with the HP 

laminate, when hot pressing. 

Well-balanced, properly constructed laminated 

composite panels can exhibit temporary warp due 

to the fact that the HPL face will usually take 13

longer to reach equilibrium with the ambient 

humidity levels than a standard HP backer sheet. 

This will result in stresses that can cause warp. 

However, as soon as the decorative HPL face has 

reached equilibrium, the stresses are relieved and 

the panel will regain its flatness. It is this ability to 

equalize and regain its flatness at any level of 

ambient humidity that is the most important 

benefit of a balanced panel construction. 

One-Sided Construction 

Applying a decorative HPL face to only one side of a 

particleboard or MDF substrate obviously creates 

an unbalanced construction. Although conditioning 

the components to the same humidity level before 

laminating is important, it will assure flatness of 

the finished laminate only at that humidity level. 

Warp may occur at higher or lower ambient 

humidity because of the difference in linear 

expansion properties between the HP laminate and 

the particleboard or MDF substrate. Failure to 

condition components prior to layup may cause the 

laminated end product to warp at all levels of 

ambient humidity. 

Rubber-based contact adhesives may reduce warp 

of one-sided constructions by providing a flexible 

glue line that allows the HPL face and substrate a 

certain amount of independent movement. Thick, 

stiff particleboard or MDF substrates will also 

minimize warp. One-sided constructions are best 

suited for applications such as countertops where 

the panel is restrained with mechanical fasteners. 

The Architectural Woodwork Institute (AWI) 3 

Quality Standard 400 restricts the amount of onesided 

panel surface area used in architectural 

cabinets. 

Warped Substrate 

Warped board should not be used as a substrate 

for laminating high-pressure laminates because the 

ultimate performance of the laminated panel will be 

unpredictable. Warp in particleboard or MDF is 

frequently due to unequal moisture pick-up in the 

top board of a stack or unit. Placing a cover board 

on top of the stack whenever the production line is 

shut down for more than a few hours can control 

this. Panels already warped should be removed 

from the stack and stored on edge to equalize for a 

day or so, until they regain their original flatness, 

before laminating. 

Temperature 

HP laminate and particleboard or MDF react 

differently when exposed to elevated temperatures. 

Particleboard or MDF will contract, whereas highpressure 

laminate will expand. If thermosetting 

adhesives are used to bond an HPL sheet to 

particleboard or MDF in the hot press, extremely 

cupped laminates will result because the plastic 

HPL is expanding while the adhesive is setting. 

After the panels are removed from the press, the 

HPL cools and contracts, resulting in cupped or 

concave finished laminated panels. A highpressure 

backer sheet should always be used when 

hot pressing. 

Cupping can also occur when contact adhesives are 

used on one-sided constructions. Some fabricators 

employ flash-off ovens to dry the contact adhesive 

on both the HPL and substrate. The HPL will 

expand when exposed to the oven heat and if the 

components are not allowed to cool properly prior 

to lamination, cupping will result. 

Delamination 

Although not as common as warp, delamination 

problems, i.e., partial or, more rarely, total failure 

of the bonding between the laminate and the 

substrate can sometimes occur. Delamination may 

be due to one or more of the following factors: 

Adhesive 

 

 

 

 

An insufficient amount of the adhesive was 

applied to the HP laminate, the substrate or 

both. 

The adhesive was not applied uniformly, 

which created areas where an insufficient 

amount of adhesive was coated. 

The adhesive on the mating surfaces was 

too dry or not dry enough. The 

manufacturer’s instructions on allowable 

optimum tack range should be closely 

followed. 

The adhesive was not stirred thoroughly 

before being applied to the mating surfaces. 

Bonding Conditions 

The bonding pressure was too low. 

Sufficient pressure should be applied to the 

assembly to ensure intimate contact 

between the mating surfaces, until the 

adhesive has set. However, care should be 

taken not to submit the assembly to a 

pressure that is high enough to affect the 

integrity of the substrate. 

The materials to be bonded were too cold. 

Most adhesive manufacturers recommend a 

minimum temperature of 70°F (21°C). 

14 

3 Architectural Woodwork Institute, 1952 Isaac Newton Square West, Reston, VA 20190, www.awinet.org

High humidity (> 80% RH) may also 

interfere with proper bonding, if the 

temperature is below 70F (21C), because 

moisture may condense on the surfaces 

during drying. 

Contamination of the surfaces to be bonded 

may cause delamination, depending on the 

extent and the nature of the contamination. 

The mating surfaces should be clean, dry 

and free of oily materials, dust, etc. 

Thermally Fused Papers 

Introduction 

Decorative papers saturated with melamineformaldehyde, 

polyester or a mixture of ureaformaldehyde 

and melamine-formaldehyde resins 

have gained wide acceptance as surfacing 

materials for industrial-grade particleboard and 

MDF substrates. Their performance characteristics 

have greatly improved over the past several 

decades and thermofused laminates are well suited 

for many end use applications such as case goods, 

institutional and hospitality furniture, office 

furniture, store fixtures, cabinetry and many 

others. 

Industrial grade particleboard and MDF are the 

most common substrates used for the production 

of Low-Pressure Laminate/thermofused melamine 

laminate (TFM) because of their uniform density, 

surface smoothness and good thickness tolerance. 

With a well-sanded surface and proper moisture 

control, MDF shows almost no telegraphing of 

wood particles. The smooth, hard surface supports 

and adheres evenly to the decorative paper and 

resists dents, damage and compression during the 

laminating process. 

TFM panels are manufactured by fusing a printed 

or solid color decorative paper saturated with a 

thermoset resin to a wood substrate, under heat 

and pressure. This is usually accomplished in a 

single opening hot press, but continuous doublebelt 

presses are also available. During the 

pressing process, the resin in the paper softens, 

flows and sets into the substrate creating a 

permanent bond between the decorative paper and 

the substrate. The resin on the decorative side of 

the paper, which is against the textured plate also 

softens, flows and sets, to become a transparent 

layer of cured resin, creating the resin-rich surface 

that gives TFM its performance characteristics. 

The physical properties of TFM panels will vary with 

the manufacturer, percentage of resin impregnated 

in the saturated paper, weight and quality of the 

decorative paper and the laminating conditions. 

Production of the Thermally Fused Decorative 

Papers 

The type of resin, amount of resin impregnation in 

the paper and the laminating process will 

determine wear, stain resistance, cleanability, and 

many other properties of the finished product. 

Decorative Paper 

Decorative papers are alpha-cellulose papers 

produced with the specifications required for use in 

the production of decorative laminates. The same 

printed papers can be used in both the HPL and the 

TFM processes; however, a solid color paper is 

usually designed for optimized performance in 

either the HPL or the TFM process and thus usually 

cannot be used interchangeably in both processes. 

The papers used by most laminators today range 

from 70 to 115 grams/m 2 , although decorative 

papers having grammages as low as 60 grams/m 2 

and as high as 140 grams/m 2 have been used. 

Once they have been impregnated with resin, the 

overall weight of the saturated decorative papers 

will typically range from 175 to 320 grams/m 2 ; 

they can be supplied in rolls or in sheets, 

depending on user specifications. 

Impregnating Resins 

The resins are introduced into the paper during an 

impregnation operation. The paper is first 

impregnated with a solution of the resin and then 

dried and partially cured (b-staged) in the curing 

ovens that are an integral component of the 

impregnation equipment (treater). 

MELAMINE – Cured melamine-formaldehyde 

resin is noted for its hardness, scratch 

resistance and color stability; it is the most 

commonly used resin in the production of 

TFM laminates. In the last two decades, 

the introduction of two-stage impregnating 

equipment has allowed producers of 

saturated papers to extend the melamine 

resin with a saturating grade ureaformaldehyde 

resin. In this instance, the 

decorative paper is impregnated by 

saturating the core of the paper with the 

extended or mixed resin, followed by 

coating of the partially dried decorative 

paper with a coat of 100% melamine resin, 

to completely seal the mixed resin in the 

core of the paper, away from its surface. 

POLYESTER – Decorative papers are 

sometimes impregnated with polyester 

resins; cure times can be adjusted through 

the use of different peroxide initiators. The 

saturated papers obtained are less brittle 

15

and less demanding in processing than 

melamine papers. In general, the polyester 

papers are similar in performance to 

melamine papers. The finished polyester 

laminate may exhibit lower scratch 

resistance than a thermofused melamine 

panel. However, polyester resins are noted 

for their stain, water, chemical, and impact 

resistance, as well as their good color 

clarity and machinability. 

PHENOLIC – Phenolic resins are also used 

for specialized decorative applications, such 

as exterior applications, where toughness 

and weather resistance are required. 

Phenolic resins are also noted for their 

chemical, stain and impact resistance. 

However, phenolics are less colorfast and 

are limited in color range. 

Impregnation of the Paper 

The amount of saturation is most often expressed 

by the thermally fused paper suppliers as resin 

content 4 , and normally ranges between 50% and 

65% of the weight of the impregnated paper. An 

important part of the impregnation process is the 

proper staging of the resin, i.e. drying and crosslinking 

of the resin to a point that will allow ease in 

handling of the paper prior to laminating and good 

performance in the laminating press. The proper 

staging is designated as the b-stage. Understaging 

may result in the impregnated sheets 

sticking together, a problem known in the industry 

as blocking. Over-staging will cause flow problems 

during lamination. The amount of resin (given as 

resin content or resin pick-up) and the degree of 

volatiles present in the paper are two 

characteristics that must be specified by the 

laminator, in consultation with the impregnator. 

Other specifications such as final dimensions of the 

impregnated paper sheets or rolls and packaging 

requirements should also be communicated to the 

impregnator. 

Laminated Panel 

Strength 

The strength and stiffness of particleboard or MDF 

surfaced on both sides with thermofused overlays 

may increase slightly, but not as dramatically as 

board surfaced with HP overlays. 

Product Performance Standard 

A performance standard for Thermoset Decorative 

Composite Panels was developed in the mid-1980s 

by the American Laminators Association (ALA- 

1985). However, this association ceased to exist in 

the early 1990s. The only North American 

Performance Standard in existence is the voluntary 

standard available from CPA and entitled: 

“Voluntary Product Standards and Typical Physical 

Properties of Decorative Overlays.” 


Because thermally fused overlays are thinner 

(0.004 – 0.007 inch or 0.10 – 0.18 mm) and thus, 

have different masking properties than HPL (0.020 

– 0.048 inch or 0.51 – 1.22 mm), the board 

substrate should be selected with greater care. 

Impregnated thermally fused paper on the lower 

end of the weight scale (impregnated weight 

between 175 grams/m 2 and 220 grams/m 2 ) will not 

cover or mask the smaller imperfections in the 

surface of the substrate like an HP laminate will. 

The factory-sanded surface quality, surface 

smoothness, density uniformity, thickness 

tolerance as well as the integrity of the surface 

layer will influence the visual appearance and 

quality of the finished TFM panel. Large flakes or 

particles may not only telegraph through the 

overlay but could also affect machining quality. 

The surface quality of the substrate becomes 

slightly less critical as the total weight of the 

impregnated thermally fused paper increases. 

Fabricators should test and evaluate substrate 

candidates and finished laminates thoroughly until 

satisfied with their appearance and performance. 

It is also a good practice to establish specifications 

with substrate and thermally fused paper suppliers, 

particularly when specific requirements are being 

requested by the customer. 


Laminating Press 

The press should ideally 

be located in an 

enclosed temperatureand 

humidity-controlled 

atmosphere to avoid 

sudden changes in 

humidity, contamination 

from airborne dirt and 

particulate and other 

factors that could affect 

the laminating process and the quality of the 

finished laminate. 

Textured caul plates are most often used to impart 

texture to the TFM panel. Caul plates may be 

16 

4 The amount of resin present in the paper can also be expressed as resin pickup, which is defined as the weight of resin as a percentage of the 

weight of the unsaturated paper. The conversion between resin content (RC) and resin pickup (PU) is as follows: %PU = %RC ÷ (100 – %RC); 

%RC = %PU ÷ (100 + %PU).

manufactured from different metals, the most 

common being steel and brass sheets; if the 

surface of the plate is to come into direct contact 

with the laminate, that surface is usually chromeplated. 

In the continuous press, texture and heat 

transfer is achieved by the use of textured belts 

that revolve around heated steel drums. Caul 

plates/belts can influence cure, appearance, 

handling and quality of the finished laminate. Caul 

plate/belt temperature, finish, and cleanliness are 

key factors for good laminating results. Heavy, 

embossed release papers are also available and 

eliminate the need for texture on the caul plates or 

belts. 


For best laminating results, the board substrate 

and saturated paper should both be brought to 

equilibrium at 35% to 45% relative humidity and 

70°F (21°C). 

Saturated Paper 

Saturated melamine papers should be stored in a 

controlled atmosphere to prevent an increase or 

decrease in their volatiles content, which will affect 

laminating performance. High humidity could also 

lead to blocking, while low humidity can dry out 

the paper and make it brittle. Polyester papers are 

not affected by humidity and have a longer shelf 

life. Extremes in temperatures should be avoided 

for all types of impregnated papers. 

Substrate 

Resin-impregnated papers are good vapor barriers, 

allowing very little moisture to escape through the 

surfaces of the substrate during pressing. 

Conversely, they provide resistance to moisture 

entering the panel after pressing. Hence, high 

moisture content of the substrate should be 

avoided as this may contribute to bonddegradation 

within the substrate, steam blows, 

warp and poor bonding between the substrate and 

the décor paper. Substrate moisture content 

should not exceed 6-8%; thus, shipping and 

storage conditions are important. Attempting to 

laminate on raw board that is either too hot or too 

cold also can negatively affect laminating 

performance and the quality of the panels 

produced. 

Substrate 

Consideration of the substrate is important when 

establishing pressing conditions, in order to avoid 

bond degradation in the board, blows, warp or 

substrate compression. This is particularly 

important when high temperatures, pressures and/ 

or long pressing times (press cycles) are used. 

With higher press temperatures, faster press cycles 

are desirable to minimize the amount of heat 

absorbed by the board substrate. Because heat is 

only required at the substrate surface to cure the 

resin in the paper, deep penetration of heat into 

the substrate should be avoided. High 

temperatures can also cause precure of the resin in 

the paper; this phenomenon is described in the 

Troubleshooting section. 

Pressing Parameters 

Some typical laminating pressing conditions for 

thermofusing saturated decorative papers to 

particleboard or MDF in a single-opening press are 

given below: 

Melamine 

Temperature: 300° to 400°F (150° to 205°C) 

Cycle: 15 to 40 seconds, not including 

press closing and decompression 

time. 

Pressure: 300 to 400 psi (2067 to 2756 kPa) 

Polyester (Range) 


Time: 30 to 90 seconds, not including 


time. 


Polyester (Ideal) 




time. 


Phenolic 




time. 

Pressure: 175 to 350 psi (1206 to 2411kPa) 

The preceding conditions apply when similar 

papers are pressed on both sides of the substrate. 

If different papers are applied, the slower curing 

paper will determine the pressing conditions. 

Hence, difficulties may occur when different face 

and back papers are used. 

Adhesives 

As mentioned above, under heat and pressure, the 

17

18 

resin in the décor paper softens, flows and sets into 

the substrate, creating a permanent bond between 

the décor paper and the substrate, without need 

for an adhesive applied to the décor paper or the 

substrate, in a separate step. 


Warp 

One of the most important requirements for most 

decorative panel constructions is their ability to 

remain flat under normal service conditions. The 

following recommendations should promote the 

production of flat laminated panels: 

Conditioning 

Materials should be stored, handled and 

conditioned as recommended. 

Extremes in temperature and humidity 

should be avoided. 

Substrate 

Warped particleboard or MDF substrates 

should not be used. 

Substrate should be stored under 

reasonable, uniform, protected warehouse 

conditions; extremes in temperature and 

humidity should be avoided. 

Saturated Paper 

 

 

 

An adequate volatiles content should be 

retained in the paper. 

The paper should not be over-aged or 

dried-out. 

The grain and machine direction of the top 

and bottom paper should be parallel. 

Balanced Construction 

 

 

Whenever possible, a balanced construction 

should be used. Proper balancing may be 

achieved by using top and bottom sheets of 

similar type, weight, etc. 

The rate of curing of the top and bottom 

papers should be similar. 


 

 

 

The press should be loaded and brought to 

full pressure as quickly as possible. 

Pressed panels should be unloaded from the 

hot press immediately after opening of the 

press, to avoid prolonged contact of the 

bottom of the panel with the hot caul plate. 

Bottom caul plates should be cool, if used 

 

 

 

 

for panel insertion. 

Pressing temperatures and cycles should 

not be hotter or longer than necessary; the 

hottest temperatures possible should be 

used to minimize the amount of time the 

panels will be exposed to heat in the hot 

press (shorter cycles). 

When using different sheets on the top and 

bottom, special attention should be paid to 

the pressing parameters to ensure proper 

cure on both sides of the panel. 

Hot pressed panels should be stacked flat 

and be well supported while cooling in 

small, covered bundles: if available, 

conveyor cooling should be used with all 

panels exposed on both sides for faster, 

uniform cooling. 

Pressed panels should be allowed to cool to 

120F or below, before machining. 

Warping may be caused by many factors in 

addition to those mentioned above. For example, 

the linear expansion of resin-saturated papers is 

often greater than that of particleboard under the 

same conditions. For more information on 

preventing warp in laminated panels, see CPA's 

Technical Bulletin entitled "Minimizing Warp in 

Laminated Particleboard and MDF." 

Mottling 

Mottling is defined as the presence of whitish areas 

on the surface of the pressed panel. Mottling is 

easier to observe on dark solid colors or dark 

printed patterns. Mottling is usually due to 

improper or uneven flow of the resin in the décor 

sheet, during the pressing process. The most 

common cause is low flow of the resin, which may 

be related to: 

Over-staging of the resin in the resinimpregnation 

process. 

Aging of the saturated paper, due to poor 

stock rotation or other reason. 

Premature aging of the saturated paper due 

to exposure to high heat during 

transportation or storage. 

Low volatile content of the saturated paper. 

This may occur during the impregnation 

process or because of exposure to dry 

ambient conditions during transportation or 

storage, due to poor packaging. 

Low resin content of the saturated paper. 

Papers that are prone to mottling, such as 

black and other deep, intense solid colors or 

some dark prints are typically produced 

with a higher resin content than most other 

papers. 

Pressing temperature is too high, not 

allowing the resin to flow before it sets.

When mottling occurs, the following changes in 

pressing parameters can often alleviate the 

problem: 

 

 

 

 

Precure 

A reduction in pressing temperature, most 

often accompanied by an increase in 

pressing cycle to ensure that proper curing 

is achieved. 

An increase in pressing pressure, as long as 

this does not lead to a deterioration in the 

substrate integrity. 

The use of cushions between the caul 

plates and the press platens to avoid hot 

spots on the caul plates. 

Pressing the same lot of impregnated paper 

on a different lot of substrate to determine 

if the mottled appearance is due to 

irregularities on the surface of the 

substrate. 

Precure is usually characterized by the presence of 

shiny lines on the bottom decorative surface of the 

pressed panels. Precure will occur when the resin 

is allowed to start setting (cross-linking) under low 

or no applied pressure. Minimizing exposure of the 

impregnated paper to heat before full pressure is 

achieved is thus the best way to avoid precure, as 

described below: 

 

 

Starvation 

The press should be loaded and brought to 

full pressure as quickly as possible. 

When pressing in a multi-opening press, 

using as few openings as possible may 

decrease the occurrence of precure, which 

is related to slow press closing times. 

Although much less common than mottling or 

precure, starvation can sometimes occur when the 

resin content of the saturated paper is too low, or 

the surface of the substrate is too open. This leads 

to an insufficient amount of resin remaining on the 

surface of the décor paper preventing complete 

sealing of the paper surface by the resin; this can 

result in open pores in the surface of the TFM that 

can cause poor water and dirt resistance. 

Starvation is easily eliminated by increasing the 

resin content specification of the saturated paper. 

VENEERS 

Introduction 

Composite panels, such as particleboard and MDF, 

are the preferred substrate for veneers, due to 

their superior surface qualities, such as their 

surface smoothness and integrity and the absence 

of knots and grain patterns. In addition, their 

uniform thickness and properties, their dimensional 

stability, strength properties and cost advantages, 

their ease of layup and good machineability, as 

well as their tendency to stay flat, make them ideal 

substrate materials. Veneered particleboard and 

MDF constructions are used in many applications 

including high-quality furniture, case goods, store 

fixtures and cabinetry. 

In most instances, thin 

veneers are bonded 

directly to substrate 

surfaces without the 

need for cross-banding, 

and show-through is 

virtually eliminated. 

Cross banding may be 

used in certain 

applications as determined and specified by the 

fabricator or end user. Fabricators need to 

evaluate boards thoroughly if they intend to omit 

cross-banding. 

The main advantages of using particleboard or 

medium density fiberboard instead of other 

substrates for these high-quality industrial panel 

constructions include: 

PB and MDF substrates are characterized 

by consistent quality core that promotes 

good bonding, homogeneous glue 

absorption and resistance to compression. 

In most cases, particleboard and MDF 

display better flatness than veneer core 

plywood. 

Decreased glue usage, which leads to 

higher labor productivity and a decrease in 

the possibility of bleed-through. 

Shorter press times are required due to 

reduced glue spreads, uniform substrate 

thickness and no inside glue lines. 

Fewer rejects from layup problems, sandthrough, 

core overlaps, trimming problems, 

and grain telegraphing. 

More uniform thickness and moisture 

content of the finished panel. 

Thinner veneers may be used without the 

need for cross-banding, with less sandthrough 

and less bleed-through, due to 

lighter glue spreads. 

Good screw holding properties with 

advanced fasteners. 

MDF has the added advantage that its 

edges can be machine-profiled and finished 

when appropriate for the application. 

Improved routability and edge finishing. 

19

20 

Depending upon veneer thickness, the strength of 

veneer panel constructions laminated in the hot 

press can increase compared to the strength of the 

unlaminated substrate, and can approach the 

stiffness and Modulus of Rupture (MOR) of solid 

wood. Cold press adhesives, such as polyvinyl 

acetates and contact adhesives, are too flexible to 

bring much improvement in panel strength. Only 

panels constructed with hot-pressed rigid 

(thermosetting) resins in conjunction with HPL or 

veneers provide this extra strength. 

Hardwood veneer, with particleboard or MDF 

substrate, may be finished utilizing many of the 

same techniques employed to finish solid wood. 

Most species accept stains and dyes very well, or 

the panels may be painted, if so desired. The 

finishing materials suppliers should be contacted 

for advice on finishing hardwood veneer. 


Because thin veneers will not cover or mask the 

smaller imperfections in the surface of the 

substrate like an HP laminate will, the board 

substrate should be selected with greater care, as 

large flakes or particles may telegraph through the 

veneer. The factory-sanded surface quality, 

surface smoothness, density uniformity, thickness 

tolerance as well as the integrity of the surface 

layer will influence the visual appearance and 

quality of the finished veneer laminate. The 

surface quality of the substrate becomes slightly 

less critical as the thickness of the veneer 

increases. 

Fabricators should test and evaluate substrate 

candidates and finished veneer laminates 

thoroughly until satisfied with their appearance and 

performance. It is also a good practice to establish 

specifications with substrate and veneer suppliers, 

particularly when specific requirements are being 

requested by the customer. 



The wood veneers and board substrates should be 

brought to equilibrium at the same temperature 

and relative humidity. Ideally, the moisture 

content of the materials to be pressed should be 

between 6%-9%, with no component exceeding 

12%. 

Hot Pressing 

Wood veneers are typically laminated to board 

substrates in a hot press. The main resin used in 

the hot pressing of veneers is a urea-formaldehyde 

adhesive system, due 

to its ability to make 

the panel more rigid, 

its fast processing 

parameters and its 

lower cost base. The 

manufacturer’s 

recommendations for 

storage, handling 

and application of the 

adhesive should be followed. The gluing practices 

described in the High-Pressure section of this 

bulletin should be followed for the production of 

good veneer laminates. The glue spread and 

laminating pressure can be calculated using the 

formulas given in the High-Pressure section. 

As with HP laminates, balanced panel construction 

is essential to minimize warp. The same thickness 

veneer should be used on both sides. If different 

species are used, the unbalanced nature of the 

construction could lead to warp, unless they have 

similar dimensional expansion behaviors in the 

same ambient conditions. 

Typical process parameters for laminating 

hardwood and decorative veneers with a ureaformaldehyde 

adhesive are shown below: 

Glue Spread: 60-70 lb/1000 ft 2 (0.29- 

3.4 kg/m 2 ) of double 

glue line 

Press Temperature: 240-250°F (115°-120° 

C) 

Press Time: 

Pressure: 

Board Moisture Content: 6%-9% 

2-1/2 to 3 minutes 

150 to 175 psi (1030 to 

1200 kPa) 

This should yield a well-bonded, virtually flat panel 

if properly balanced and stored, before and after 

pressing. The finished panel is usually very stable, 

and checking of face veneers after layup is almost 

non-existent. Long and/or hot pressing conditions 

are detrimental to the substrate panels when 

laminating with veneers. The time required to cure 

the applied glue lines is all that is necessary. 

Cold Pressing 

Wood veneers can also be laminated to board 

substrates in a cold press with contact adhesives, 

polyvinyl acetate or casein adhesives. These 

adhesives may be less rigid than heat-activated 

resin systems. Cold pressing is generally 

conducted in small batches. Clamp times will vary 

depending on the type of adhesive used. Times as 

low as 5 to 10 minutes are possible, but set times 

under pressure are usually longer because of 

slower moisture evaporation. Water-based

adhesives may induce checking in the wood 

veneers. It is important to allow adequate set 

times before machining. 

Delamination 

Delamination may occur when: 

Adhesives 

The most common adhesives used in hot pressing 

are urea-formaldehyde systems. The adhesives 

most commonly used in cold pressing are contact 

adhesives, polyvinyl acetate and casein systems. 

Cross-linked isocyanate resins have also been used 

successfully in cold pressing. 

 

 

 

Too much water is present due to a high 

adhesive coverage or to the use of an 

adhesive with too low of a solids content. 

A high internal steam pressure develops 

because the press cycle time is too long or 

the platen temperature is too high. 

The surface of the substrate is porous and 

absorbs too much moisture. 


Warp 

Warp is seldom a problem with balanced panel 

constructions. The most common causes of 

warped veneered panels are listed below. 

Veneer 

Use of a very thin substrate with thick 

veneer faces. 

Different moisture contents, species, 

density or thickness of the face veneers 

that lead to an unbalanced construction. 

Stress areas in the veneers (tension wood, 

burls, cross grain, etc). 

Non-uniform sanding. 

Veneers on top and bottom do not have 

parallel grain (one veneer perpendicular to 

the other) 

Adhesive 

Application of too much or too little 

adhesive. 

Use of a low solids content adhesive. 

Unbalanced glue spreads between one side 

of the substrate and the other. 

Inadequate cure of the adhesive in the hot 

press. 

Over-drying of the adhesive in the press 

before, during or after pressing. 

Process 

 

 

 

 

 

 

Loading and/or unloading the hot press too 

slowly. 

Poor stacking of the panels before and/or 

after pressing. 

Uneven heating of the platens. 

Pressing of two thin panels in the same 

opening. 

Unstacking the panels or machining them 

before they are properly cooled. 

Unbalanced sanding. 

VINYL LAMINATION 

Introduction 

Lamination of vinyl films on 

flat substrates is accomplished 

with either a “quick stamp” flat 

press line or a roller 

continuous press line. Flat 

presses typically have a longer 

dwell time that provides 

increased wetting (resin 

penetration into the substrate). Roller presses are 

more compact physically, are faster and can 

accommodate a variety of substrate lengths. 

The machines that comprise a continuous film, roll 

laminating production line are a combination of 

automatic assembly devices, with interconnecting 

conveyors that apply and bond the laminating film 

to one or both sides of the board substrate. They 

can be very basic cold laminating lines or very 

sophisticated hot laminating lines, depending upon 

the end product requirements, production volume, 

and the fabricator’s capabilities. 

Cold Laminating System 

A cold or wet laminating line is a rather simple, 

straightforward laminating system used for the 

application of some vinyl films. A typical line 

would automatically clean both sides of the 

substrate, apply a uniform coat of adhesive over 

the board’s surface with a direct roll coater and 

laminate the film to the substrate with roll 

pressure. The adhesive can be applied to the vinyl 

films also, as it is let off the feeding roll. In most 

instances, no substrate sanding is required and no 

energy is needed to dry or reactivate the adhesive. 

In this process, open time (time elapsed between 

adhesive application or activation and application 

of laminating pressure) is critical. In addition, the 

laminated panels must be stacked under pressure 

for 24 to 48 hours to allow the adhesive to cure 

completely before any subsequent processing can 

be conducted. 21

22 

Hot Laminating System 

The hot laminating system used to laminate films 

that do not have a pre-applied adhesive is more 

complex than the cold laminating system, but 

offers more capabilities. A typical production line 

would include a material infeed, sander, substrate 

cleaner, direct roll coater, drying oven, second roll 

coater, second drying oven, adhesive heat 

reactivator, film roll stand, heated laminating roll, 

cut-off knife to slit loose film between panels, 

embosser (if required), foil edge and end trimmer, 

and a laminated board stacker. 

Two coats of thermoplastic adhesives are generally 

applied to the board’s surface: the first coat seals 

the board and the second coat provides the layer 

needed to achieve the required bond between the 

film and the board substrate. After exiting the 

second drying oven, the dry adhesive on the board 

substrate is reactivated with heat just before the 

film is applied, using a heated elastomeric nip roll. 

After lamination, the surface can be tic-embossed 

to enhance a wood grain pattern and machined inline. 

Finished laminates can be shipped almost 

immediately after processing. 

Hot lamination is more labor and energy intensive 

than cold lamination, but offers a larger lamination 

capacity. 


The surface quality of the board has a significant 

influence on the surface appearance of the finished 

laminate. Thinner decorative overlays do not have 

good masking properties and any imperfections in 

the substrate surface can telegraph through the 

film. Surface color, smoothness, sanding, face 

layer integrity as well as uniform thickness 

tolerance are essential. For some film applications, 

the board surface may have to be filled or sanded 

with a 150 or 180-grit belt to provide a tighter, 

smoother surface. 



The vinyl film manufacturer’s recommendations for 

storage and conditioning prior to lamination should 

be followed closely. Storage conditions can be 

especially critical for materials with a pre-coated 

adhesive and topcoat. 

The substrate should be conditioned to ensure a 

moisture content in the range of 6-8%. The 

conditioning time should be long enough to achieve 

uniform moisture content throughout the thickness 

of the substrate. 


It is difficult to give general guidelines on 

temperatures, pressures, drying ovens, etc., for roll 

lamination of films to board surfaces, because 

there are so many variables in materials, adhesive 

systems, laminating lines, and fabricators’ 

capabilities. However, the recommended gluing 

practices described in the HPL section are key 

factors in producing attractive, well-bonded 

laminates. 

In most instances the processing information 

needed can be obtained from the suppliers of the 

vinyl film, adhesives and laminating machinery. It 

is essential to work with those suppliers and with 

the substrate manufacturer to determine the 

process parameters that will yield the desired 

appearance and performance of the finished 

laminated product. A most important and often 

overlooked requirement for quality lamination is 

correct and uniform temperature of the substrate 

before the first press. 

Adhesives 

Several different adhesive systems are used for 

bonding vinyl films to board substrates. In most 

instances, they are applied by a direct roll coater. 

The adhesive manufacturer’s instructions for 

storage, handling, and application should be 

followed closely. During winter, the temperature 

around the glue tank should not dip below 68°F 

(20°C). 

Cold Laminating 

Vinyl films may be laminated with two-part epoxy 

adhesives or water-based adhesives such as 

ethylene/vinyl acetates, acrylics or vinyl chloride/ 

vinylidenes. The water-based systems should be 

evaluated closely, due to their tendency to raise 

board surface particles and fibers that could 

telegraph through the vinyl film surface. A onepart 

urethane adhesive system that cures by 

absorbing moisture from the air and/or the 

substrate is also used by some fabricators. 

Hot Laminating 

Solvent-based adhesives such as urethanes, 

polyesters, vinyl/urethanes, polyester/urethanes 

and epoxy/urethanes have been found suitable for 

bonding vinyl films to board substrates. All are 

two-part systems that must be combined prior to 

use. They all require forced air-drying to dissipate 

solvents and need heat reactivation before the film 

is laminated. Full bond strengths are obtained 

within 12 to 24 hours.

VINYL – THERMOFORMING 

Introduction 

Thermoforming encompasses a number of 

processes. Two of these processes, vacuum 

forming and membrane pressing, involve 

laminating vinyl overlays onto a substrate. Both 

processes are used to create three-dimensional 

pieces in which the vinyl conforms to the profile on 

all sides as well as any routed areas in the center 

of the piece. Vinyl films require an adhesive for 

bonding to the board substrate. As the name 

implies, the thermoforming process uses heat to 

soften the vinyl film and then form the film tightly 

to the profile. Typical profiles consist of medium 

density fiberboard or high density fiberboard (MDF 

or HDF) shaped and routed into cabinet doors, 

decorative moldings and contoured tops. 

The use of these techniques is expected to 

continue to grow due to the design flexibility that 

thermoforming offers and increasing environmental 

pressures from various state regulations and the 

revised 1990 Clean Air Act, to reduce emission of 

volatile organic compounds (VOCs). 

Vacuum Forming 

Vacuum forming has been used with vinyl films for 

decades. A variety of finished products can be 

produced for the furniture and consumer 

electronics market using this process, including 

speaker baffles, rounded tops, drawer fronts and 

handles. 

Membrane Pressing 

Membrane pressing 

was used exclusively 

for laminating wood 

veneers until the 

1980s, when the 

technology was 

expanded to vinyl 

films. Membrane 

presses have the 

capability of 

laminating more complex profiles and providing 

better heat resistance, but require heavy gauge 

rigid films. 

Membrane presses form the film by pulling with 

vacuum from below and pushing the film into the 

profile with a pressurized silicone membrane from 

the top. The film is forced into the profiles by the 

pressure differential between the membrane above 

and the vacuum below the film and routed part. 

Membraneless presses use the film as the 

membrane to separate pressure on top and 

vacuum below. Thermoforming equipment can be 

purchased in a number of configurations from 

several different manufacturers. 


MDF and HDF (high-density fiberboard) are the 

most commonly used substrates in thermoforming, 

with the density of the substrate depending on the 

application. The fine core of these substrates 

allows routed parts to be glued and laminated with 

minimal telegraphing. Other porous substrates are 

sometimes used in vacuum forming. The surface 

of the substrate must be smooth and void of 

chatter, sanding marks, router marks or other 

board defects that will telegraph through the vinyl 

film. The routed areas present a more open 

surface and tend to absorb water-based adhesives 

more readily, which may lead to some fiber pop in 

those areas. 



Vacuum forming machines form the heat-softened 

vinyl to the substrate by vacuum application under 

the board and film. Vinyl films for vacuum forming 

are usually plasticized to make them more flexible 

and range in gauge (thickness) from 0.005 inch 

(0.13 mm) all the way up to 0.060 inch (1.5 mm). 


The membrane press process requires careful 

planning for the laminated panels to meet the 

quality requirements. Several key factors to 

consider include: 

Membrane 

The selection of the proper membrane is critical to 

successful vinyl film pressing. Only properly 

formulated, 100% silicone rubber membranes 

should be used with vinyl films. Non-compatible 

natural rubber membranes commonly used to 

press wood veneer will impart the vinyl film with a 

yellow discoloration. Membrane suppliers should 

be able to offer technical assistance in determining 

compatibility between the vinyl and the 

membrane. 

Vinyl Film Gauge 

Membrane press films are usually rigid films. The 

film gauge ranges from 0.010 to 0.020 inch (0.25 

to 0.50 mm), with some films as thick as 0.040 

inch (1.0 mm) being used in special applications. 

The selection of the vinyl film gauge depends on 

the radius of the draw and the shape of the profile. 

23

Tests should be conducted to determine which 

thermoforming vinyl film gauge meets the needs of 

the shape to be pressed. 


Successful pressing requires consistent processing 

conditions. The temperature, pressure, preheat 

time and pressing time all must be optimized. 

Enough heat is required to soften the vinyl for 

forming and to activate the adhesive. Pressing 

cycles range between 1½ and 4 minutes. A typical 

cycle includes preheating for 30 to 60 seconds, 

followed by pressing for 1 to 3 minutes. Heat 

settings during pressing are different from press to 

press, but generally the vinyl and glue line are 

heated to a minimum of 160°F (71°C), typically 

around 195°F (90°C). Pressures usually range 

from 2.5 to 5 bars (36 to 72 psi). 

Adhesives 

The application of the adhesive is critical to a 

smooth even surface. Uneven adhesive application 

can show through the film surface and result in 

uneven adhesion. 


The most common adhesives used in vacuum 

forming are polyurethanes, which are sometimes 

catalyzed. 


An adhesion promoting primer is usually applied to 

the back of the film. The predominant adhesive 

type is a cross-linkable water-based polyurethane 

spray (PUD) applied to the substrate prior to 

pressing. In certain applications, a noncrosslinking 

hot melt adhesive is pre-applied to the 

film, followed by re-rolling of the film. 


REFERENCES 

William Herschberger, "The Anatomy of High- 

Pressure Decorative Laminates", Wood and 

Wood Products, June 1985. 

Bill Bair, "A Look at Decorative Paper 

Laminating", Wood and Wood Products, June 

1985. 

Robert F. Snider, "Using Adhesive with Core 

Materials", Wood and Wood Products, June 

1985. 

B.G. Heebink, "Importance of Balanced 

Construction in Plastic-Face Wood Panels", U.S. 

Forest Service Research Note Fpl-021, 1963. 

B.G. Heebink, "Reaction to Unbalance Panel 

Constructions to Slow and Rapid Changes in 

Relative Humidity", U.S. Forest Service 

Research Note Fpl-0166, 1996. 

B.G. Heebink, H.H. Haskell, "Effect of Heat and 

Humidity on the Properties of High Pressure 

Laminates", Forest Products Journal, XII (11): 

542, 1962. 

"Particleboard from Start to Finish," Composite 

Panel Association, Gaithersburg, Maryland, 

1996. 

"MDF from Start to Finish", Composite Panel 

Association, Gaithersburg, Maryland, 1991. 

Bob Martin, "Continuous Film Laminating 

Systems", Furniture Production, November 

1970. 

Donald Jones, "Tips on Cold Press Particleboard 

Laminating", Wood and Wood Products, 

November 1969. 

Miriam Feinseth, "Dry Printing Decorative 

Techniques and Applications for Wood 

Products", Furniture Manufacturing 

Management, December 1980. 

NEMA LD3-2005 standard, "Performance, 

Application, Fabrication and Installation of 

High-Pressure Decorative Laminates", National 

Electrical Manufacturers Association, 2005. 


 

 

 

 

Too little heat can tear the film and result in 

poor adhesion. 

Too much heat can result in embossing loss 

and sticking of the film to the membrane. 

Too little pressure can lead to poor forming 

and poorly sealed edges. 

Too much pressure can tear the film, 

increase strike-through and lead to 

premature wearing of the membranes. 

24 

Lengthening the cycle allows lower temperatures 

and pressures to be used, but will slow down 

production.

APPENDIX I – GLOSSARY OF TERMS 

ADHESIVE 

A substance capable of holding materials 

together by surface attachment. The term is 

used to cover the bonding of sheet material 

and is synonymous with glue. 

BACKER 

A non-decorative overlay used on the back of 

composite panel constructions to protect the 

substrate from changes in humidity and to 

balance the panel construction. 

BALANCED CONSTRUCTION 

A laminated composite panel construction that 

typically has a similar overlay on both surfaces, 

which reduces or eliminates warp when 

subjected to uniformly distributed moisture 

changes. 

BASIS WEIGHT 

Most often used to characterize paper products, 

in the decorative laminates industry. The basis 

weight is defined as the weight in pounds of a 

ream (3000 square feet) of paper. 

BLOCKING 

BLOW 

When referring to saturated papers, sticking of 

the sheets or layers of the roll together without 

any means of separating them without inflicting 

permanent damage to the sheets or roll. 

A localized delamination caused by steam 

pressure build-up during the hot pressing 

process. Blows may result from excessive 

moisture, excessive or poor resin distribution 

or high press temperatures. 

CALENDERED 

For polymers, passing of the film through 

heated rolls, moving at varying rates, to reduce 

the film thickness. 

CHECKING 

Ruptures along the grain that develop during 

seasoning either because of a difference in 

radial or tangential shrinkage or because of 

uneven shrinkage of the tissue in adjacent 

portions of the wood. 

CUP 

Deviation, flat-wise from a straight line 

stretched across the width of the panel. 

DELAMINATION 

An actual separation of a laminate from a 

substrate. 

EMBOSSING 

EPOXY 

A process by which the surface of the panel 

product is given a relief effect. This can be 

accomplished with a pressure roll or a 

patterned caul plate in a hot press. 

A two-component thermosetting adhesive 

typically used for laminating medium and 

heavy gauge vinyls. Epoxy adhesives are 

generally blended 1:1 (resin to hardener) by 

volume and are roll-coated either to the 

backside of the vinyl web or to the board 

surface. 

FIBER RAISE 

Face fibers that are raised above the 

surrounding surface appearing as a rough 

surface. Usually caused by excessive 

absorption of moisture. 

GRAMMAGE 

Most often used to characterize paper products, 

in the decorative laminates industry the 

grammage is defined as the weight in grams of 

one square meter of paper (gsm). 

GRIT SIZE 

Refers to coarseness of an abrasive material on 

a sanding belt. The lower the grit label, the 

coarser the abrasive material. 

HOT MELT 

A thermoplastic adhesive that is 100% solids 

and is applied molten to form a bond upon 

cooling. Hot melts differ from conventional 

liquid adhesives because they set by cooling 

rather than by absorption or evaporation of 

water or solvent. 

25

LINEAR EXPANSION 

A measure of growth along the length and/or 

width of a material when exposed to conditions 

from low to high humidity, stated as a 

percentage of the original dimensions. 

MACHINE DIRECTION 

The orientation that corresponds with the 

direction in which the product moved through 

the machine that manufactured it. 

RELATIVE HUMIDITY 

Ratio of the amount of water vapor present in 

air to that which the air would hold at 

saturation at the same temperature. 

RESIN CONTENT 

In the decorative overlay industry, the resin 

content is the percentage of resin in the 

saturated paper in relation to the total weight 

of the saturated paper. 

MIL 

A thickness measurement typically used for 

vinyls and papers. One mill equals onethousandth 

of an inch or 0.001 inch. 

MODULUS OF ELASTICITY (MOE) 

A measure of the board’s resistance to 

deflection or sagging when loaded as a simple 

beam. Value stated in pounds per square inch 

(psi) or Newtons per square millimeter (N/ 

mm 2 ). 

MODULUS OF RUPTURE (MOR) 

An index of the maximum breaking strength of 

the board when loaded as a simple beam. 

Value stated in pounds per square inch (psi) or 

Newtons per square millimeter (N/mm 2 ). 

MOISTURE CONTENT 

The amount of water in wood and expressed as 

a percentage of dry weight. 

RESIN PICKUP 

In the decorative laminates industry, the resin 

pick-up is the percentage of resin in the 

saturated paper in relation to the weight of the 

paper before impregnation. 

SAND-THROUGH 

A condition where the face layer has been 

sanded off, exposing the core. 

SOLVENT-BORNE ADHESIVE 

An adhesive containing polymeric materials 

dissolved in volatile organic solvents, to which a 

small percentage of cross-linker is added to 

obtain certain desired performance properties, 

such as higher heat resistance. This type of 

adhesive is typically used on a “hot line” 

laminator where it is applied to the board or 

film surface, dried and then heat activated prior 

to a hot roll laminating station. They are nongrain 

raising and exhibit good coatability, high 

heat resistance and excellent bond strengths. 

26 

MOTTLING 

Irregular visual appearance in an area or entire 

surface of a finished panel. 

PRECURE 

Curing of a resin before pressing. 

POLYURETHANE DISPERSIONS 

Polyurethane dispersions are used for the 

membrane pressing of vinyl films and veneers 

to a MDF core. They can be used in 

conjunction with a hardener for higher heat 

resistance if required. The hardener level is 

usually 5% by weight and should be added with 

very good agitation. Polyurethane dispersions 

are typically spray-applied to the MDF and then 

air-dried before mating with the vinyl film or 

veneer in the press. 

SCREW-HOLDING 

A measure of the force required to withdraw a 

screw directly from the face or edge of a board, 

stated in pounds (lbs) or Newtons (N). 

SUBSTRATE 

TACK 

A material that provides the surface onto which 

an adhesive or coating is spread. 

Viscosity or degree of “stickiness” of an 

adhesive, which reflects its state of dryness or 

advancement of cure, prior to bonding. 

TELEGRAPHING 

Transfer of substrate surface defects through 

the thickness of the overlay material.

THERMOPLASTIC ADHESIVE 

Resins or adhesives that harden at room 

temperature and re-soften upon exposure to 

heat. 

THERMOSETTING ADHESIVE 

Resins or adhesives that cure at room 

temperature or in the hot press by chemical 

reaction to form rigid bonds that are not resoftened 

by exposure to heat (cross-links). 

UNBALANCED CONSTRUCTION 

When individual components or layers of a 

laminate do not respond equally to changes in 

moisture, thus causing warp. 

VOLATILES CONTENT 

Weight loss of a saturated paper when heated 

to bone-dry, expressed as a percentage of the 

weight of the saturated paper. 

WATERBORNE ADHESIVE 

WARP 

Water-based adhesives are formulated 

synthetic polymers (usually vinyl acetate or 

ethylene vinyl acetate polymers). These 

products are generally used for paper 

laminating, where the adhesive is applied to 

the web and/or board surface and tacks up 

through one or more heated rolls that combine 

paper to board. 

Deviation of a panel from a flat plane due to 

unbalanced construction, excessive moisture 

pickup, wetting or other unfavorable 

exposures. 

REFERENCES 

“MDF from Start to Finish”, Composite Panel Association, Copyright 1991. 

“Glossary of Terms”, Laminating Materials Association Inc., Copyright 2001. 

A.J. Panshin & C. De Zeeuw, Textbook of Wood Technology, Vol. 1, 1964. 

“Storage and Handling of Particleboard and MDF,” Composite Panel Association, Gaithersburg, 

Maryland, 2000. 

27

The information in this document is 

believed to be reliable. However, the 

determination of suitability of this 

information for any use or application 

remains the sole responsibility of the 

user. 

No guarantees, representations or 

express or implied warranties are made 

regarding the accuracy and 

completeness of this information, and 

the Composite Panel Association (CPA) 

assumes no responsibility or liability for 

any loss or damage through reliance 

upon it. 

Composite Panel Association 

Main Office 

18922 Premiere Court 

Gaithersburg, Maryland 20879-1574 

301-670-0604 Fax 301-840-1252 

99 Bank Street, Suite 701 

Ottawa, Ontario K1P 6B9 

613-232-6782 Fax 613-232-8386 

Toll Free 1-866-4COMPOSITES 

www.pbmdf.com 

Composite Panel Association 

The Composite Panel Association (CPA), 

founded in 1960, represents the North 

American composite panel industry on 

technical, regulatory, quality assurance and 

product acceptance issues. CPA General 

Members include 39 of the leading 

manufacturers of particleboard, medium 

density fiberboard and hardboard. Together 

they represent nearly 95% of the total 

manufacturing capacity throughout North 

America. CPA also brings together the 

complete value chain affiliated with the 

composite panel industry. CPA’s 200 

members worldwide, primarily in the US and 

Canada, are committed to product 

advancement and industry competitiveness. 

Associate Members include manufacturers of 

furniture, cabinets, decorative surfaces and 

equipment, as well as laminators and 

distributors. 

CPA is a vital resource for both producers 

and users of industry products. As an 

accredited standards developer, CPA writes 

and publishes industry product standards. It 

also participates in the standards 

development work of ANSI, ASTM and 

others, sponsors product acceptance 

activities and works with federal and state 

agencies and model building code bodies. In 

addition, CPA conducts product testing and 

third-party certification programs, while 

helping manufacturers create in-plant quality 

control programs. CPA offers the first ANSI 

accredited Environmentally Preferable 

Product (EPP) certification program, which 

certifies composite panel products that are 

100 percent recycled and low emitting. 

Downstream manufacturers who use EPP 

certified substrates will also be able to 

market their products as environmentally 

preferable through this program, which 

offers an alternative to “for profit” green 

certification programs. Outreach and 

education are also focal points of the CPA. 

The Association publishes industry 

performance data, produces a series of 

technical bulletins and develops publications 

to inform key audiences about the attributes 

of industry products. 

Copyright © 2007 Composite Panel Association. All rights reserved. Any reproduction of this document in whole or in part 

by any means is expressly prohibited unless specific written authorization is obtained from the Composite Panel Association.

Laminating Composite Panels - Flakeboard

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